HAZARDOUS

WASTE DISPOSAL
BY THERMAL
OXIDATION

HAZARDOUS WASTE DISPOSAL

BY THERMAL OXIDATION
INTRODUCTION
Thermal oxidation has proved to be an effective and safe method for the disposal of a wide variety
of hazardous industrial wastes. Virtually all organic compounds can be thermally oxidized with an
assured level of destruction. John Zink Company has over 2300 thermal oxidizer installations in
service worldwide, destroying an array of hazardous and non-hazardous organic wastes.
The basic thermal oxidation system, shown in Figure A, consists of a refractory-lined vessel called
the Thermal Oxidizer (T.O.), burner, stack, and combustion controls. The oxygen for combustion
comes either from ambient air or is contained in the waste gas stream. Ambient air may be
inspirated by natural draft or forced in by a fan.

Castable
Refractory
Lining

Stack

Brick Lining W/
Castable Refractory
Back-Up Lining

Thermal
Oxidizer

Waste Stream

Castable
Refractory Floor

Fuel

Combustion Control
Package

Burner

Air
Figure A: Basic Thermal Oxidation

Ideally, the flue gas resulting from high-temperature oxidation of hydrocarbons (HC) contains
CO2 , H2O, N2 , O2 and some acceptable levels of oxides of nitrogen (NOx ) and oxides of
sulfur (SOx). In reality, the flue gas from a combustion process contains CO2 , H2O, N2 , O2
and some concentration of carbon monoxide (CO), unburned hydrocarbons (UHC), NOx and
SOx .

PRODUCTS OF COMBUSTION
IDEAL

REAL

CO 2 , H 2O, O 2, N2 , NO XA *, SO XA *
FG
* Sub A designates acceptable level.

CO2 , H2 O, O 2 , N2 , NOX, SO X
UHC,CO

Environmental concerns require that the flue gas exiting a TO meet certain emission
requirements mandated by local and/or federal regulatory authorities. Thus, it is important not
only to destroy the organic portion of the waste completely, but also to limit the quantities of
pollutants which are produced by the combustion process or were originally in the waste but
not destroyed by combustion. For example, oxides of sulfur and C12/HCI produced by
thermally oxidizing wastes containing sulfontated or chlorinated components must be removed
down-steam. Similarly, inorganic salts or ash contained in the waste are unaffected by
combustion and must be removed to meet particulate emission requirements.

Meeting CO and UHC regulations is accomplished by the correct selection of TO resident

time, operating temperature and turbulence - the three Ts of combustion. Figure B is a plot
or residence time versus destruction efficiency for CO and HC at various temperatures. It
shows that CO and HC destruction efficiency increase as residence time and operating
temperature increase.

Figure C is an example of how this information is used to determine concentration of UHC and CO
in the flue gas. In this example, we assume methane is being burned with 25% excess air in a
horizontal T.O., having a residence time of 1.0 seconds and operating at a temperature of T2 . Air
injected into the T.O. is in addition to the 25% excess air and is used to lower methanes 3200 F
adiabatic temperature to T2 .
The destruction efficiencies obtained from the graph for CO and HC are 99.88 % and 99.985 %.,
respectively. The heat and mass balance calculations determine flue gas concentrations of 7.1 and
56.8 ppm V (dry) for unburned HC (assumed as CH4 ) and CO, respectively.

EXAMPLE:
What is the concentration of CO and unburned hydrocarbon in the flue gas
when the residence time is 1.0 second and operating temperature is T2 ?
Use air to cool operating temperature to T2 .
CO graph reading = 99.88 %
HC graph reading = 99.985 %
CH

3200 F

Heat Loss

Combustion Air
Horizontal T. O.

Basis 1 mole of CH
CH4 + 2O2
CO2 +
Stoichiometric Air =
125% Air (Burner) =
Flue Gas:
N2
=
O2 =

2H2O
9.52
11.90
9.40
0.50

Stack

( 2/0.21 )
( 9.52 x 1.25 )
( 11.9 x 0.79 )
((11.90 - 9.52) x 0.21)

Flue Gas @ 3200 F : ( Figure D)

CO = 1
H2O = 2
N2 = 9.4
O2 = 0.5
Assume after subtracting heat loss, 12 moles of air will cool flue gas to T2 .
Flue Gas @ T2 :
CO2 = 1
2
H2O =
N2
= 18.88
( 9.4 + (12 x 0.79) )
O2
=
3.02
( 0.5 + (12 x 0.21) )
-4
CH4 =
1.5 x 10
1 ( 1 - 0.99985 )
CO =
1.2 x 10-3
1 (1 - 0.9988 )
Total dry flue gas =
22.9 moles
[CH4 ] =
6.6 ppmv dry basis
[CO]
=
52.4 ppmv dry basis
Figure C : Example Problem

Figure D is a plot of adiabatic flame temperature, volume percent combustibles and volume
percent oxygen versus percent of stoichiometric combustion air for # 2 fuel oil and natural gas.
The figure indicates a theoretical flame temperature of 3200F when methane is burned with
125 percent of stoichiometric combustion air (25% excess). In the previous example, air was
used to cool the 3200F products of combustion leaving the burner to the TO exit temperature
of T2.

Meeting stringent pollution control regulations governing the amount of inorganic acids (SOx,
NOx, H3PO4, Cl2/HCl) and particulate matter in the exit flue gases requires the use of
additional equipment downstream of the basic TO system. This paper furnishes the reader
with a method of selecting the most appropriate waste disposal process.

WASTE CATEGORIES
Wastes are supplied to a disposal process in the form of either gas, liquid or solid, or a
combination thereof. Thus, wastes can be systematically divided into the categories of gas,
liquid, solid, gas+solid, liquid+solid and gas+liquid. Table 1, Industrial Waste and Pollutant,
lists these categories in the left-hand column. Note the absence of a gas+liquid category. A
gas+liquid waste, both fluids, versus a gas-only or liquid-only waste, requires the choice of an
appropriate burner rather than a process.

The second column lists a typical waste for each category, with the related waste pollutant(s) listed
in the third column. For example, a fume stream which is predominantly air containing
approximately one percent (10,000 ppmV) HC is listed as a gas waste, whereas a biosludge is
listed as a liquid+solid waste. Obviously, this second column does not contain all known industrial
wastes. However, it is likely that a particular waste is sufficiently similar to a listed waste so an
appropriate process can be chosen.
The fourth column is a list of process numbers which identify processes applicable to dispose of
waste listed in the corresponding row. For example, Process 6 is used to treat a gas+solid stream
consisting of CO, H2O and small combustible particulate.

DISPOSAL PROCESSES
The eight similar but separate processes to dispose of industrial wastes are described by the
following text and diagrams.
Gas or Liquid Waste - High Levels of NOx and/or SOx
The following six diagrams illustrate each of the six configurations of a process to dispose of
either a gas or liquid waste which produces a flue gas containing acceptable amounts of SOx
and/or NOx. Configuration 1.1 is simply a T.O. which is supplied with waste, fuel and
combustion air. Fuel is required when the wastes combustion energy is insufficient (endothermic)
to produce an appropriate operating temperature. An exothermic waste requires a cooling medium
such as excess air, steam, or water for temperature control.
WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

Tail Gas Organic

Acid

FG, NOXA, SOXA

FG, NOXA
Flue Gas

Waste

Air
Fuel
Stack

T. O.

Configuration 1.1 : Waste Process

Configuration 1.2 is the T.O. fitted with a heat recovery boiler. A boiler with an economizer can
recover as much as 85 % of the heat energy supplied to the T.O. by the waste and the fuel.
WASTE
Gas
Liquid

EXAMPLE
Tail Gas Organic
Acid

PRODUCTS OF OXIDATION
FG, NOXA, SOXA
FG, NOXA

Steam
Flue Gas

Waste
Air
Fuel
T. O.

Configuration 1.2 : Waste Process

Boiler

Stack

Configuration 1.3 shows a T.O. fitted with a gas-to-gas heat exchanger. In the heat exchanger, the
hot flue gas from the T.O. is used to heat the incoming waste gases. This method of heat recovery,
when heating a 60 F waste gas to 800 F with a 1600 F operating temperature, can reduce a
16.8 MM Btu/hr without preheat fuel requirement, to approximately 9 MM Btu/hr.
(Refer to Figure 1A for savings.)
WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

Tail Gas Organic

Acid

FG, NOXA, SOXA

FG, NOXA
Flue Gas

Waste

Air
Fuel
T. O.

H. Exchanger

Stack

Configuration 1.3 : Waste Process

Value of Recovered Flue Gas Heat

(B ased on 5000 cfm of inert w aste gas and 1600F operating tem perature)
70

60

Fuel Savings (%)

50

40

30

20

10

0
0

200

400

600
W aste Preheat Tem p (F)

800

1000

1200

Configuration 1.4 is a T.O. fitted with a gas-to-gas exchanger and a heat recovery boiler. The heat
exchanger heats incoming combustion air or waste gases, and the boiler further extracts the heat
available in the flue gas discharged from the exchanger. This configuration offers flexibility in the
amount of steam produced versus fuel usage.
WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

Tail Gas Organic

Acid

FG, NOXA, SOXA

FG, NOXA
Steam

Waste

Flue Gas

Air
Fuel
T. O.

H. Exchanger

Boiler

Stack

Configuration 1.4 : Waste Process

Configuration 1.5 illustrates a Catalytic Oxidizer fitted with a gas-to-gas exchanger. The
heat exchanger preheats contaminated air which is routed to chamber containing catalyst
material. The catalyst causes oxidation of the HC to occur at much lower temperatures than
in a thermal oxidizer, thus greatly reducing the fuel usage. The HC content of the air is
generally limited to less the 0.75 % because of temperature limits of the catalyst.

WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

Tail Gas Organic

Acid

FG, NOXA, SOXA

FG, NOXA
Flue Gas

Contaminated Air

Fuel

Catalytic Oxidizer

H. Exchanger

Configuration 1.5 : Waste Process

Stack

Configuration 1.6 displays a regenerative oxidizer which uses refractory packing to absorb and
transfer heat to the outgoing or incoming air stream. Inlet and outlet ductwork, valves and an
induced draft blower provide the means for the contaminated air to enter and exit the chambers
independently. The paths of flow are controlled by action of inlet and outlet valves. HC contents
is usually limited by the lower flammability limit instead of by overall HC concentration.
WASTE

Gas
Liquid

EXAMPLE

PRODUCTS OF OXIDATION

Tail Gas Organic

Acid

FG, NOXA, SOXA

FG, NOXA

T. O.
Chamber No 2

Chamber No 1

Chamber No 3

Contaminated Air

Flue Gas
Purge

Fuel

Stack

Configuration 1.6 : Waste Process

Gas or Liquid Waste - High Levels of SOx or Cl2/ HCl
The following two diagrams show configurations of a process to dispose of either a gas or liquid
waste which produces flue gas containing excessive amounts of SOx or Cl2 / HCl.
Configuration 2.1 consists of a T.O., a quench section which cools the flue gas to its saturation
temperature by directly contacting it with water, two adiabatic absorbers which remove inorganic
acids and chlorine, and a vent stack. Water is used in the first absorber to remove a majority of the
HCl from the flue gas. The residual HCl and virtually all the entering Cl2 leaves the absorber with
the flue gas. A second absorber with caustic is used when either the Cl2 or HCl in the flue gas
exiting the first absorber exceeds allowable levels. This occurs when excessive Cl2 is formed in the
T.O. (see Figure 2A for HCl/Cl2 equilibrium) or when the first absorber is used to make acid.
WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

VCM
PCB
Pesticides

FG, NOXA, Cl2 / HCl

H2 O

Flue Gas

Caustic

Hydrochloric
Acid

Waste

Salt
Effluent

Air
Fuel
T. O.

Quench

Configuration 2.1 : Waste Process

Absorber

Caustic Scrubber

Stack

Figure 2A: Equilibrium Constant vs. Temperature

Configuration 2.2 consists of a T.O., a heat recovery boiler which produces steam in
cooling the flue gas to 500 F, two absorbers, and a vent stack. The first absorber is fitted
with a lower section of ceramic packing which cools the 500 F flue gas to saturation
temperature prior to its entry into the acid absorption section, and the second absorber
removes residual HCl and CI2 .

WASTE

EXAMPLE

PRODUCTS OF OXIDATION

Gas
Liquid

VCM
PCB
Pesticides

FG, NOXA, Cl2 / HCl

Waste

Steam

Flue Gas

Caustic
H2O

Hydrochloric
Acid

Air

Salt
Effluent

Fuel

T. O.

Boiler

Acid
Absorber

Configuration 2.2 : Waste Process

10

Caustic
Scrubber

Stack

When the waste stream is highly exothermic, a cooling medium such as air or water or steam is
added to the T.O. to control the flue gases to the boiler.

Flue Gas

Figure 2B is an equipment representation of the

system shown in Configuration 2.2., consisting of a
horizontal T.O., firetube boiler, quench column, acidabsorber, caustic scrubber, and and integral stack.

Stack

Make-Up
Caustic
Solution

Scrubber

Salt Solution

Waste Liquid
(Exothermic)

Steam

Absorber

Combustion Air

Acid

Waste Liquid
(Exothermic)

Fuel
T. O.

Boiler

Quench Section

Figure 2B : Waste Process

Gas or Liquid - High Levels of NOx
Figure 3 is a block diagram of a two-stage combustion process to dispose of either a gas or liquid
that, if oxidized in a single-stage combustion process, would produce a flue gas containing
excessive amounts of NOx. It consists of the following components:
A reduction furnace in which a high-temperature reducing (less than stoichiometric air)
environment converts the fuel into H2 , H2O, CO, and CO2 , and the NOx present into N2 .
A quench section which cools the flue gas to approximately 1400 F by directly
contracting it with a cool recycle gas.
A ReOx furnace which converts the H2 to H2O and CO to CO2 .
A heat recovery boiler which produces steam in cooling the flue gas to 350 F
An vent stack.
11

WASTE
Gas
Liquid
Waste

CO2
H2
CO
H2O
N2

EXAMPLE
Tail Gas Organic
Acid

PRODUCTS OF OXIDATION
FG, NOXA, SOXA
FG, NOXA

Flue Gas

Steam
Recycle Flue Gas
Air

Fuel
Air

Reduction Furnace

Quench Section

ReOx Furnace

Boiler

Stack

Figure 3 : Waste Process

Recycle flue gas cooling in lieu of steam or water is an integral part of this process and helps
maximize heat recovery.
The purpose of the cooling step between the reducing stage and re-oxidation stage is to lower
the fine T.O. temperature. As shown in Figure 3A, a plot of NOx concentration versus
temperature, the amount of thermal NOx produced is a function of operating temperature and
the amount to excess oxygen. For example, when 2% O2 is present, an operating temperature of
1600 F has an equilibrium NOx value of 42 ppm V; and at 2000 F, it has NOx value of over
200 ppm V. Thus, it is desirable to operate at the lowest practical temperature. Another
consideration is to oxidize the H2 and CO present to meet air quality regulations. The design
becomes a trade-off between the amount of H2 and CO allowed and the amount of NOx
allowed in the final product of combustion. Figure 3B is a schematic of a NOxIDIZER
system.

12

WASTE
Gas
Liquid

EXAMPLE
Tail Gas Organic
Acid

PRODUCTS OF OXIDATION
FG, NOXA, SOXA
FG, NOXA

Recyled Flue Gas

Combustion Air

Steam

Feed Water

Fuel

Steam

Reduction Furnace

ReOx Furnace

Boiler

Stack

Figure 3B : NOxIDIZER System

Gas or Liquid Waste - Produces Cl2/HCl and NOx

Figure 4 is a example of a process to dispose or either a gas or liquid that produces a flue
gas containing Cl2/HCl and excessive amounts of NOx. It consists of several equipment
systems as follows:
A reduction furnace in which a high-temperature reducing environment converts NOx
to N2 , Cl to HCl and fuel to H2, H2O, CO and CO2.
A quench section which cools the water gas to approximately 1400 F by directly
contacting it with recycle gas.
A T.O. which converts the H2 to H2O, CO to CO2 and allows the HCl concentration to
reach equilibrium.
An adiabatic absorber fitted with a lower section of ceramic packing which cools the
500 F flue gas to saturation temperature prior to its entry into the acid absorption section
which removes the inorganic acids.
An vent stack.
Recycled flue gas cooling is an integral part of this process to maximize heat recovery.

13

WASTE
Liquid

EXAMPLE
Chlorinated Amine
CO2
H2
CO
H2O
N2

Waste

PRODUCTS OF OXIDATION
FG, Cl2/HCl, NOX

Flue Gas

Steam

H2O Or
Caustic

Recycled Flue Gas

Air

Fuel
Air

Reduction Furnance Quench Section

ReOx Furnace

Boiler Acid Or Salt Absorber STACK

Stack

Figure 4 : Waste Process

If the chlorine-bearing waste steams are separate from nitrogen-bearing waste streams, the
chlorine stream can be admitted to the T.O. directly. The segregation of streams would result
in a smaller reduction furnace and, for endothermic wastes, would reduce the amount of
auxiliary fuel used.

Gas or Liquid Waste - High Levels of Particulates

The following three equipment examples show configurations of a process to dispose of either
a gaseous or liquid waste which produces flue gas containing excessive amounts of particulate
matter.
Configuration 5.1 consists of the following equipment systems:
A T.O.
A quench section which cools the flue gas to its saturation temperature by directly
contacting it with water.
A wet scrubber which removes the particular matter.
A vent stack.
A major advantage of the wet scrubber is its ability to remove both particulates and any
corrosive gases (SO2, HCl) in a single operation.
WASTE

EXAMPLE

LIQUID/SOLID

NaCI SOLUTION
POLYPROPYLENE/CATALYST

PRODUCTS OF OXIDATION
H2 O

FG, NOXA, PARTICULATE

2
SALT SOLUTION
OR SUSPENSION

WASTE

FLUE GAS

AIR
FUEL
T. O.

QUENCH

WET SCRUBBER

Configuration 5.1 : Waste Process

14

STACK

Configuration 5.2 consists of the following:

A T.O.
A conditioning tower which, by directly contacting with water cools the flue gas either
600 F or 350 F, depending upon the dry particulate removal system selected.
An electrostatic precipitator (ESP) or a baghouse
A vent stack
WASTE
LIQUID / SOLID

EXAMPLE
PRODUCTS OF OXIDATION
NaCI SOLUTION
FG, NOXA, PARTICULATE
POLYPROPYLENE/CATALYST

FUEL

ESP

FLUE GAS

WASTE
INJECTION

AIR
THERMAL OXIDIZER

600 F

AIR
AND / OR
H2O

DRY SALT

OR 350 F
BAG HOUSE

CONDITIONING
TOWER

STACK

DRY SALT

Figure 5.2 : Waste Process

Configuration 5.3 consists of the following major components:
A T.O.
A conditioning tower fitted with a SaltMaster TM system which lowers the flue gas to
below salt fusion temperature by directly contacting it with recycle flue gas.
A heat recovery boiler which produces steam in cooling the flue gas to 350o F.
Either an ESP or baghouse for particulate removal.
And an unlined vent stack.
The SaltMasterTM system keeps the salt building up in the bottom of the conditioning chamber
Salt build-up can cause operating and maintenance problems. Recycle gas is used for cooling to
maximize heat recovery.
WASTE
LIQUID / SOLID

EXAMPLE
PRODUCTS OF OXIDATION
NaCI SOLUTION
FG, NOXA, PARTICULATE
POLYPROPYLENE/CATALYST

FUEL

FLUE GAS

ESP
WASTE
INJECTION

AIR
THERMAL OXIDIZER

WATER

AIR
AND / OR
H2O

350 F

DRY SALT

STEAM
BOILER

OR
BAG HOUSE

CONDITIONING
TOWER
SaltMaster TM

DRY SALT
SALT SOLUTION OR SUSPENSION

Figure 5.3 : Waste Process

15

STACK

Figure 5A is a schematic of a down-fired salt system with a wet particulate removal system
(High Velocity Scrubber). Alternatively, a venturi scrubber may be used. The schematic shown
in Figure 5B is of a down-fired salt system with heat recovery.

Natural Gas

Fuel Oil or Waste Liquid (Exothermic)

Air or Steam Atomization
Burner Assembly
Waste Liquid Injection (Exothermic)
Air or Steam Atomization

Thermal Oxidizer

Vent Stack
Quench
Pot

Mist Eliminator

Make-Up Water
High Velocity Scrubber

Combustion
Air Blower

Acid or Salt
Solution or
Suspension

Make-Up Water

Figure 5A : Down-Fired Salt System

Natural Gas

Fuel Oil or Waste Liquid (Exothermic)

Air or Steam Atomization
Burner Assembly
Waste Liquid Injection (Exothermic)
Air or Steam Atomization

Vent Stack

Recycled Gas
Thermal Oxidizer
Recycled Gas
Boiler
Conditioning
Tower

Steam

Salt Solution
and / or
Suspension

Economizer

BagHouse

Make-Up
Water

Salt Master TM
Combustion
Air Blower

Dry
Salt

Soot Blowers

Figure 5B : Down-Fired Salt System with Heat Recovery

16

Waste Containing Combustible Fine Solids Acceptable Levels of NOx and/or SOx
The following two block diagrams show configurations of a process to dispose of a waste-containing
combustible fine solids (less than 500 microns particle size), which produces flue gas containing
acceptable amounts of SOx and/or NOx.
Configuration 6.1 consists of a cyclonic T.O. in which a high radial gas velocity causes the denser
solid particles to be preferentially slung to the wall, thus markedly increasing their retention time.

WASTE
GAS / SOLID

EXAMPLE
CO + H2/C

PRODUCTS OF OXIDATION
FG, NOXA

FLUE GAS

HOPPER

AIR
FUEL
CYCLONIC T.O. STACK

Configuration 6.1 : Waste Process

Configuration 6.2 shows a cyclonic T.O. fitted with a heat recovery boiler which produces steam
to lower the flue gas temperature to 350 F.

WASTE
GAS / SOLID

EXAMPLE
CO + H2/C

PRODUCTS OF OXIDATION
FG, NOXA

STEAM
FLUE GAS

HOPPER

AIR
FUEL
CYCLONIC T.O.

BOILER

Configuration 6.2 : Waste Process

17

STACK

Gaseous Wastes Containing Combustible Fine Solids Acceptable Levels of NOx and/or SOx
The following two diagrams illustrate configurations of a process to dispose of a gaseous waste
containing a combustible fine solid (less than 500 microns) which produces flue gas containing
acceptable amounts of SOx and/or NOx and excessive amounts of particulate.
Configuration 7.1 consists of the following equipment:
A cyclonic T.O.
Either a quench column, which by directly contacting the flue gas with water, cools it to its
saturation temperature; and a wet scrubber which removes the particular matter or a conditioning
tower, which by directly contacting the flue gas with water and/or air cools it to either 600 F to
350 F, depending on the dry particulate removal system selected.
An ESP or baghouse.
An unlined vent stack.
WASTE
GAS / SOLID
SOLID

EXAMPLE
CO + H2/C + ASH
COAL FINES

PRODUCTS OF OXIDATION
FG, NOXA,PARTICULATE
FG, NOXA,PARTICULATE

HOPPER

H 2O
Quench

AIR

FLUE GAS

Wet Scrubber

FUEL
Make-Up Water

CYCLONIC T.O.
Conditioning
Tower

ESP
OR

STACK

DRY ASH

350 F
DRY ASH
BAG HOUSE

Configuration 7.1 : Waste Process

Configuration 7.2 consists of the following major equipment:
A cyclonic T.O.
A hot cyclone for large particulate removal and/or conditioning tower which by directly
contacting the flue gas with recycle gas cools it to below ash fusion temperature.
A heat recovery boiler which produces steam in cooling the flue gas to 350 F.
Either an ESP or baghouse for particulate removal.
An unlined vent stack.
Recycle gas is used for cooling to maximize heat recovery.
18

WASTE
GAS / SOLID
SOLID

EXAMPLE
CO + H2/C + ASH
COAL FINES

PRODUCTS OF OXIDATION
FG, NOXA, PARTICULATE
FG, NOXA, PARTICULATE

STEAM
HOPPER

FLUE GAS
ESP

AIR

350 F
DRY ASH

FUEL

DRY ASH

CONDITIONING
TOWER

CYCLONIC T.O. HOT CYCLONE

BOILER

OR

STACK

350 F
Recycled Gas

DRY ASH
BAG HOUSE

Configuration 7.2 : Waste Process

Wastes Containing Combustible Solids
Figure 8 is a diagram of a process to dispose of a waste that contains combustible solids in the
particle size range of 10 to 500 microns that produces a flue gas containing excessive amounts of
NOx. It consists of the following major components:
A cyclonic reduction furnace in which a high radial velocity, high temperature, reducing (less
than stoichiometric air) environment converts the bound nitrogen to N2 and the fuel to water gas.
A quench section which cools the water gas to approximately 1400 F.
A heat recovery boiler which produces steam in cooling the flue gas to 350 F.
An unlined vent stack.
WASTE
GAS / SOLID
SOLID
Water Gas
HOPPER

CO2
H2
CO
H2O
N2

EXAMPLE
MELAMINE SLURRY
DNT CELLULOSE

PRODUCTS OF OXIDATION
FG, NOx
FG, NOx

FLUE GAS

STEAM
RECYCLED GAS
AIR

FUEL
AIR
CYCLONIC REDUCTION
FURNACE

QUENCH

T.O

BOILER

STACK

Figure 8 : Waste Process

Recycle flue gas cooling is an integral part of the process to minimize NOx formation and
maximize heat recovery.

19

SUMMARY
The description of pollutant control processes found in this paper is a tool which can be used
to identify the basic process needed to destroy pollutants in various types of waste streams.
Although this cookbook approach is a simplified version of the real world method of
specific equipment selection, it provides a good general understanding of what process is
best-suited for the destruction of various pollutants found in todays industries.

20